Defender (1993+). Manual — part 14

MAINTENANCE

ST445

POWER STEERING FLUID RESERVOIR

WARNING:

Do

not remove the filler cap when the

engine is hot because the cooling system is
pressurised and personal scalding could result.

1.

Clean and remove the reservoir cap.

2.

Check that the fluid

I

S

up to the lower mark on

the dip

stick.

Top-up

if

necessary and refit

cap.

1.

When removing the filler cap, first turn

i t

a

little way very gently and gauge any pressure
that may be behind

it.

Allow all pressure to

escape slowly before fully releasing the cap.

2.

With

a

cold engine, the coolant level should

be just to the top of the level indicator post
situated in the expansion tank below the filler
hole.

BATTERY

Check Specific Gravity

The specific gravity of the electrolyte should be
checked using a battery hydrometer. The readings
should be as follows:
Temperate climate

below

26.5°C

(80°F)

as

commissioned for service, fully charged 1.270 to

1.290 specific gravity.

CHECK COOLING SYSTEM COOLANT

As expected during normal sewice, three-quarter
charged 1.230 to 1.250 specific gravity.

Refer to the 'COOLING SYSTEM' section for details

If the specific gravity should read between 1.190 to

of anti-freeze and to SECTION 09 for anti-freeze

1.210, half-charged, the battery must be bench

protection quantities.

charged and the electrical equipment in the car

With a cold engine, the expansion tank should be

should be checked.

approximately half full.

Tropical

climate

above

26.5°C

(80°F)

as

commissioned for service,

fully

charged 1.210 to

WARNING: Do not remove the filler cap when the

1.230 specific gravity.

engine i s hot because the cooling system is

As expected during normal sewice, three-quarter

pressurised and personal scalding could result.

charge 1.170 to 1.190 specific gravity.

If the specific gravity should read between 1.130 to

1. To remove the filler cap, first turn it

1.150, half-charged, the battery must be bench

charged and the electrical equipment on the car
should be checked.

anti-clockwise a quarter of a turn and allow all
pressure to escape, before turning further in
me same direction to lift i t off. When replacing
the filler cap it is important that it is tightened
down fully, not just to the first stop. Failure to
tighten the filler cap properly may result in
water loss, with possible damage to the
engine through overheating.

22

REVISED:

OCT

1993

MAINTENANCE

Check and Top-Up Electrolyte Level

RENEW

BRAKE

SERVO

FILTER

1.

Wipe all dirt and moisture from the battery

1 .

Remove the nuts securing the master cylinder

top.

to the servo.

2.

Remove the filler cover, If necessary add

2.

Release the clip retaining the brake pipe to

sufficient distilled water to raise the level to
the top of separators.

the clutch pipe.

3. Separate the master cylinder from

the

servo.

4

Disconnect the vacuum hose from the servo.

switch at the rear

of

the pedal box.

pedal box.

withdraw the clevis pin and washer

Replace the filler plugs or manifold lid.

3.

Avoid the use of a naked light when

5.

Disconnect the Lucars from the stop lamp

4.

In hot climates

it

will

be necessary to top up

6.

Remove the blanking grommets from the

5.

In very cold weather

it

is essential that the

7. Remove the split pin from

the

clevis and

examining the cells.

the battery at more frequent intervals.

vehicle is used immediately after topping up,

to

ensure that the distilled water is thoroughly

mixed

with

the electrolyte. Neglect

of

this

precaution may result in the distilled water

freezing and causing damage to the battery.

Battery terminals

6. Remove battery terminals, clean, grease and

refit.

7. Replace terminal screw: do not overtighten.

Do

not use the screw

for

pulling down the

terminal.

8. Do NOT disconnect the battery cables while

the engine

IS

running

or

damage to alternator

semiconductor devices may occur. It

is

also

inadvisable to break

or

make any connection

in the alternator charging and control circuits
while the engine

is

running.

9. It

is

essential

to

observe the polarity

of

connections

to

the battery, alternator and

regulator, as any incorrect connections made

when

reconnecting cables

may

cause

irreparable damage

to the

semiconductor

devices.

CAUTION: If

a

new

battery is fitted to the vehicle,

it should

bo

the

same

type as fitted to the

vehicle when new. Alternative batteries may vary

in sire and terminal positions and this could be

a

possible fire hazard if the terminals

or

leads

come into contact with the battery clamp

assembly. When fitting a new battery ensure that
the terminals and leads are clear of the battery
clamp assembly.

8.

Remove the four nuts securing the servo to

the pedal box and remove the servo

RE-ISSUED: FEB

1993

23

MAINTENANCE

ST1533M

9.

Pull back the dust cover.

10.

Release the end-cap.

11.

Cut the filters to remove them from the shaft.

DRIVE BELT TENSIONING

WARNING:

Do not attempt

to

check belt tension

or make adjustments with the engine running.
Serious

injury

could result.

Each drive belt should be tight enough to dnve
without undue strain on the bearing. Using moderate
finger pressure at the point indicated

in

the

illustration, belts should deflect

0.5 mm

per 25 mm.

Deflection beyond this limit may cause

a

loud

whining or knocking noise and intermittent drive.

FAN/WATER PUMP DRIVE BELT ADJUSTMENT

1.

Loosen

the

jockey wheel securing bolt and

12.

Clean the filter seating and fit the new filters

adjust the wheel position until the correct

noting that they must be cut to fit over the

tension is obtained.

shaft

2. Tighten the securing bolt and recheck the

Fit the end-cap and dust cover and refit the

deflection.

servo and master cylinder to the vehicle
reversing the removal procedure. Use a new
split pin to secure the clevis.

13

14

Test the brakes

THROTTLE PEDAL ADJUSTMENT

1.

After renewing the throttle cable. remove any

slack in the cable by adjustment of the cable
adjuster at me engine end.

2. Depress the throttle pedal, by hand, to the full

extent of the throttle linkage, and adjust the

pedal stop screw to take up all clearance
between the screw and scuttle panel. Make

sure that no strain is placed upon the throttle
linkage.

24

REVISED: OCT

1993

ST1835M

ST3424M

MAINTENANCE

AIR CONDITIONING COMPRESSOR DRIVE BELT
DEFENDER

110

ADJUSTMENT

POWER STEERING PUMP DRIVE BELT

Before adjustment of the steering pump belt

is

carried

out,

the alternator drive belt must be loosened to

facilitate accurate adjustment.

1 .

Loosen the Jockey wheel securing bolt and

adjust the wheel position until the correct

1.

Loosen the steering pump pivot nut and

tension is obtained. Tighten the securing bolt

adjustment bolt.

2.

Ensure the pump

I

S

free to rotate

on

the

mounting.

DO

NOT

lever pump, loosen fixings

further if necessary.

3.

Carefully lever against the pump bracket to
tension the belt. Where access is restricted, a
lever

with

one end cranked 5° to 10° may be

fed down between the water pump and
distributor. Place the lever against the steering
pump bracket, carefully levering from the
water pump/front cover

and recheck the deflection

ALTERNATOR AND POWER STEERING PUMP
DRIVE BELT ADJUSTMENT

An additional pulley, bolted to the front of the
steering pump pulley is used as a guide for the

alternator drive belt. Before adjustment of the
steering pump belt is carried out, the alternator belt
must

be

loosened to facilitate accurate adjustment.

Before adjusting the alternator drive belt ensure the

steering pump belt is correctly adjusted.

CAUTION:

Do

not

lever against the steering

pump

casing.

Damage

to

the casing may result

in

oil

leaks.

4.

Check the belt tension at the mid-point of

the

longest span, the belt should deflect 0.5 mm

per

25

mm

of

belt

run between pulley centres

Tighten the steering pump adjustment bolt and
pivot nut.

5.

Recheck the belt tension.

6.

Carry out alternator belt tensioning

1 .

Alternator drive belt

2.

Steering pump drive belt

3.

Steering pump and guide pulley

4

Alternator drive belt tensioner

REVISED: OCT

1993

2 5

RR3909M